Packaging architecture for a data server

ABSTRACT

A rack-mount data server includes a housing, a plurality of data server components supported by the housing, the components including at least one peripheral storage device, a logic chassis for the data server, at least one disk drive on which the data server stores files, and at least one power supply, and a plurality of racks coupled with the housing to accommodate the data server components, the racks including a first topmost rack accommodating the at least one peripheral storage device and a second rack accommodating the logic chassis, the housing supporting the second rack underneath the first rack as the second topmost rack. The data server also includes a front door and a top door, the top door and the front door being interlockable with each other such that when the top door and the front door are in their closed positions, one of the top door and the front door locks the other of the top door and the front door in its closed position. A security system monitors the closed and/or locked status of a number of components, including the front door.

CROSS-REFERENCE TO RELATED APPLICATION

The subject matter of this application is related to the subject matterof commonly assigned, concurrently filed U.S. Design application No.29/042,986 (Atty. Docket No. 1451.06-US-01), which is incorporatedherein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to computing devices, and more particularly, topackaging architectures for arranging and enclosing data servercomponents.

2. Description of Related Art

Data servers are well-known in the art for linking computing resourceswithin networks. Data server components, including hard disk drives,peripheral storage devices, power supplies, and logic components, areavailable in a variety of configurations.

A number of prior art data server configurations waste significantinternal space, and thus are unnecessarily large, because the dataserver components are significantly spaced apart to allow room forrepair and replacement tasks. Up to 40% of the internal space in someservers is empty, and thus wasted, for the sake of easy serviceability.Other configurations sacrifice ready access and serviceability forcompactness, and are consequently extremely difficult to repair andmaintain. Some smaller servers, for example, place peripheral storagedevices and a logic chassis at the same level within the server,necessitating disassembly and/or removal of the storage devices toservice the logic chassis, and vice versa. Additionally, many internalcomponents of certain data servers can be accessed only from the side ofthe server for repair and/or maintenance. Accessing these componentsthrough the side of the server necessitates a two-to-three foot spacebetween adjacent servers, rolling a server away from an adjacent server,and/or disconnecting a server from its power source. A need has arisen,therefore, for a data server that is both compact and serviceable, andthat does not require side access for standard repair and maintenance.

Other typical data server configurations present a significantdisadvantage in that the data server components that are accessed andused most often, e.g. peripheral storage devices, are placed at leastpartially at an operator-inconvenient location. Locating peripheralstorage devices at floor level, for example, requires an operator tostoop down to supplement, swap or service the peripheral storagedevices. A need has arisen, therefore, for a more user-friendly dataserver providing easier access to often-used components.

Additionally, many prior art servers are vulnerable to unauthorizedaccess at a number of points, and/or provide inadequate safety/warningdevices to indicate that access is being attempted to the interior ofthe data server which potentially could compromise the integrity of datastored on the server. A need has arisen, therefore, for a data serverthat minimizes the number of access points while providing effectivesecurement and monitoring of those access points. In this regard, mostprior art servers fail to prevent unauthorized removal of the serverdoors. A need has thus arisen for a server that simply but effectivelyprevents unauthorized door removal and/or access to the interior of theserver.

Finally, a number of prior art servers fail to adequately controlairflow through and past essential components of the server, causingheat buildup and thermal-induced failure. Recirculation of warm airthrough the server, for example, has been problematic in a number ofprevious devices. A need has arisen, therefore, for a server thatprovides better air circulation and thus more effectively cools the dataserver components.

SUMMARY OF THE INVENTION

To address the above and other disadvantages, a rack-mount data serveraccording to an embodiment of the invention includes a housing, aplurality of data server components supported by the housing, and aplurality of racks coupled with the housing to accommodate the dataserver components. The data server components include at least oneperipheral storage device, a logic chassis for the data server, at leastone disk drive on which the data server stores files, and at least onepower supply. The racks coupled with the housing include a first,topmost rack accommodating the at least one peripheral storage device,and a second rack accommodating the logic chassis. The housing supportsthe second rack underneath the first rack as the second-topmost rack.

According to one embodiment, the first rack is supported by the housingto move from a housed position within the housing to an extendedposition at least partially outside the housing, allowing access to thelogic chassis from the top of the data server. This embodiment alsopreferably includes a plurality of slides, the first rack being mountedon the slides to move linearly to its extended position. Additionally,the logic chassis preferably includes a movable cover, which isswingable to an open position when the first rack is moved to itsextended position. The cover preferably is pivotally mounted to thelogic chassis to swing into a space that was occupied by the first rackin its housed position. In this way, the present invention allows formore current operation access to peripheral storage devices by locatingthem in the first on the top of the housing, while still allowing easyaccess to the logic chassis located on the second rack.

According to another aspect of the invention, a rack-mount data serverembodiment includes a housing, a plurality of data server components, aplurality of racks coupled with the housing to accommodate the dataserver components, and front and top doors. The top door and the frontdoor are interlockable with each other, such that when the top door andthe front door are closed, one of the top door and the front door locksthe other of the top door and the front door in its closed position.According to one embodiment, the front door includes a lip and the topdoor includes an abutting surface, such that the lip of the front dooroverlaps the abutting surface of the top door to prevent the top doorfrom opening. In this way the present invention provides a mechanism toeffectively prevent unauthorized door removal.

This data server embodiment also preferably includes at least onedetection device, coupled with the front door and/or the top door andwith a system management unit of the data server. The detection devicepreferably signals the system management unit upon attempted access todata server components from outside the data server via the door.According to various embodiments, the detection device signals thesystem management unit when the door is unlocked and/or opened. Further,the detection device preferably includes a microswitch, butalternatively can include other similar components. Additionally, thisdata server embodiment preferably includes a system interrupt switch,such as a system reset switch or a system abort switch, for example. Thesystem interrupt switch preferably is placed so as to be accessible onlyvia one of the top door and the front door.

Also according to this embodiment, at least one detection devicepreferably is coupled with a peripheral access door that allows accessto at least one peripheral storage device of the data server. Thedetection device preferably signals the system management unit uponattempted access to the peripheral rack via the peripheral access door.Further, the data server preferably includes a detection device coupledwith a cover of a logic chassis of the data server, to signal the systemmanagement unit upon attempted access to the logic chassis via thecover. The logic chassis preferably includes a plurality of printedcircuit modules that are inaccessible from the back of the data server.

According to another aspect of the invention, a rack-mount data serverembodiment includes a housing, a plurality of data server components, aplurality of racks to accommodate the components, and a front doorcovering the front side of the housing. The front door preferablyincludes a mesh structure on at least a portion of an exterior surface,to allow airflow through the front door. A plurality of fans arepositioned to move air from outside the front of the data serverhousing, through the mesh structure of the front door, and toward theback side of the housing. At least one of the fans preferably includes afan speed sensor to signal the system management unit of the data serverupon deviation of fan speed from a predetermined level. The meshstructure preferably extends a majority of the length of the front doorto allow airflow therethrough, and the mesh structure preferablyincludes at least one screen.

According to another aspect of the invention, a side-by-side arrangementof multiple rack-mount data servers includes a plurality of immediatelyadjacent data servers arranged side-by-side to form a row of dataservers. Each data server includes a housing, a plurality of data servercomponents including a plurality of disk drives, a plurality of racksaccommodating the data server components, a front door, and at least onehinge coupled with the front door and with the housing to cause thefront door to open without interfering with an immediately adjacent dataserver. The disk drives preferably include a plurality of plug-and-playdisk drives. Each data server according to this embodiment alsopreferably includes a top door having at least one hinge to cause thetop door to open without interfering with an immediately adjacent dataserver. In this way, multiple servers in accordance with the presentinvention can be positioned side-by-side without requiring the user tomove the servers to allow for side panel access when service isrequired.

According to another aspect of the invention, a rack-mount data serverincludes a housing, a plurality of data server components, a pluralityof racks to accommodate the data server components, and a front door.The data server according to this embodiment also preferably includes atleast one hinge to cause the front door to move to an open positionwithout interfering with an immediately adjacent data server. The hingepreferably defines a substantially vertical pivot axis passing throughan edge of the front door. The data server also preferably includes atop door and associated hinge to cause the top door to open withoutinterfering with an immediately adjacent data server. The hingepreferably includes a stepped section and the front door preferablyincludes a protrusion, the protrusion being located within the steppedsection to prevent vertical removal of the front door when the frontdoor is in its closed position. The protrusion preferably is removedfrom the stepped section to allow vertical removal of the front doorwhen the front door is in its open position.

Other important aspects and embodiments, such as, but not limited to,spill resistance, internal wiring arrangements, I/O channel/disk driveconnections, and the construction and loading of the disk drive racksand other racks, will be described below.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will be described with reference to theFigures, in which like reference numerals denote like elements and inwhich:

FIG. 1 is a perspective view of a data server with external skins on,according to an embodiment of the invention;

FIG. 2 is a rear perspective view of the FIG. 1 data server;

FIG. 3 is a perspective view of the FIG. 1 data server with a peripheralaccess door in an open position;

FIG. 4 is a perspective view of the FIG. 1 data server with top, frontand rear doors open;

FIG. 4A is a perspective, close-up view of a front hinge structureaccording to one embodiment of the invention;

FIG. 4B is a perspective, close-up view of a top portion of the FIG. 1data server;

FIG. 5 is a rear perspective view of the FIG. 1 data server with top,front and rear doors open;

FIG. 6 is a perspective view of the FIG. 1 data server showing movementof the peripheral rack and card cage lid, according to one embodiment;

FIG. 7 is a rear perspective view of a data server as shown in FIG. 6;

FIG. 8 is a perspective view of the FIG. 1 data server, with externalskins off;

FIG. 9 is a rear perspective view of the FIG. 1 data server, also withexternal skins off;

FIG. 9A is a rear perspective view similar to FIG. 9 but illustratedwith additional features;

FIG. 10 is a perspective view of a peripheral rack according to oneembodiment;

FIG. 11 is an exploded view of the FIG. 10 peripheral rack;

FIG. 12 is a perspective view of a disk drive rack according to anembodiment of the invention;

FIG. 13 is an exploded view of the FIG. 12 rack;

FIG. 14 is a perspective view of a power supply rack according to oneembodiment;

FIG. 15 is an exploded view of the FIG. 14 rack;

FIG. 16 is a perspective view of a card cage rack according to oneembodiment;

FIG. 17 is a rear perspective view of the FIG. 16 card cage rack; and

FIG. 18 is a front view of a side-by-side arrangement of multiplerack-data servers according to one embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

This application describes and illustrates data server packagingarchitecture in various arrangements, including skins-on, skins-off,doors-open and doors-closed arrangements. The invention, however, is notnecessarily limited to data servers. On the contrary, embodiments of theinvention have application to a wide variety of computing hardware, notjust data servers. Therefore, while preferred embodiments of theinvention will be described with respect to data servers and data serverarchitecture, the invention is not necessarily limited to these devices.

FIGS. 1-9A of the application show rack-mount data server 10, with aplurality of skins covering internal housing frame 15 (FIG. 8) toprovide an outer surface of data server 10. The skins include front door20, rear door 35, top door/lid 30, right side wall 25, and left sidewall 27 (FIG. 5). In its closed position (e.g. FIG. 1), front door 20covers the front side of housing 15, and in its open position (e.g. FIG.4), front door 20 allows access to internal components of data server10, to be described below, from the front side of housing 15. Similarly,top door 30 is positioned to cover the top side of housing 15 when topdoor 30 is in a closed position and to allow access to at least one ofthe data server components from the top side of housing 15 when top door30 is in an open position.

According to one embodiment, front door 20 is formed of a moldedplastic, although other materials, such as urethane, for example, alsoare contemplated according to the invention. Additionally, front door 20preferably is provided with at least one mesh structure 23, such as ascreen, to provide a macrofilter that keeps large particulate matter outof data server 10. Mesh structure preferably extends over a majority ofthe length of front door 20, for example approximately 3/4 of thelength, but of course could also extend less than a majority of thelength. To better filter incoming air, mesh structure 23 preferablyincludes two superposed screens, the combination of which also producesan aesthetically pleasing patterned effect, e.g., a moire effect.

Right side wall 25, left side wall 27, top door 30 and rear door 35 allpreferably are formed of sheet metal, although, as with front door 20,alternative materials are also contemplated. The sheet metal preferablyis zinc-plated and then painted, to maximize endurance and aestheticappeal, or can be left bare or provided with other coatings.

Front door 20 preferably is opened by inserting a proper key into lock90. Of course, other, non-key locking mechanisms also can be used.Although rear door 35 of the illustrated embodiment is opened merely bysliding latch 38 to one side, a locking rear door also is contemplatedaccording to the invention. Top door 30 preferably does not include adedicated locking mechanism. According to the illustrated embodiment,however, top door 30 is held in its closed position by front door 20, aswill be described.

Rear door 35 is designed to swing between open and closed positions onexternal hinges 37 (FIG. 2), and also is designed for easy removal fromhousing 15. For purposes of this description, for rear door 35 as wellas for front and top doors 20, 30, the term "open position" should beinterpreted to mean open and attached to housing 15, or partially orcompletely removed therefrom.

Behind its doors 20, 30, 35 and side walls 25, 27, housing 15 of dataserver 10 supports a plurality of data server components containedwithin a computer unit. Data server 10 preferably includes a pluralityof racks, five in the illustrated embodiment, each of which can beassociated with a different function of the data server. Of course, anumber of racks other than five also can be provided, and multiple rackscan be associated with a single function or a single rack can beassociated with multiple functions. Although the configuration andpositioning of the various racks in typical rack-mount data serverswaste a large amount of space, data server 10 according to the inventionmaximizes efficient space usage and thus improves upon the standard wayof thinking in the art, while still maintaining a "look" that does notnecessarily stand out as unusual.

The racks of data server 10 will now be described in greater detail.Topmost rack 40 (FIG. 4) preferably is a peripheral rack thataccommodates at least one peripheral storage device 43, such as one ormore floppy disk drive, CD ROM drive, boot drive, tape drive, and/orother peripheral storage devices, especially peripheral storage devicesthat require user access in the form of insertion or withdrawal of astorage medium from the peripheral storage device. Front door 20preferably includes peripheral access door 75, which in the illustratedembodiment is hinged on front door 20 to swing down and exposeperipheral devices 43, as shown, for example, in FIG. 3. Peripheralaccess door 75 also can be completely removable from front door 20.Given the frequency with which peripheral devices are generallyaccessed, peripheral door 75 typically is not locked. Of course,however, a lock could be provided to create a more secure environment.According to one embodiment, peripheral door 75 is composed primarily ofan at least semi-transparent plexiglass 76, surrounded by molded frame77, although of course other materials and/or material combinations alsoare contemplated.

Immediately under peripheral rack 40 in the embodiment shown in FIG. 4,for example, is logic chassis 45, also referred to as a card cage rack.Card cage rack 45 supports card cage 47, which includes a plurality ofprinted circuit modules that provide the basic logic functions for thedata server and generally are among the most valuable components of themachine. To cool the modules, card cage rack 45 preferably includes aplurality of fans 41, to be described in greater detail below.

Beneath card cage rack 45, housing 15 supports disk drive racks 50, 55.Racks 50, 55 do not have to be completely populated with disk drives,although they are completely populated in the illustrated embodiments.In the event a user of data server 10 desires to use only a portion ofthe possible total population, the empty space created by the absence ofone or more disk drives 57 preferably is covered by a flat plate orother object, although of course the empty space can also be left open.Disk drives 57 preferably are of the plug-and-play type and preferablyare hot-swappable, meaning that they can be replaced upon failurewithout turning off data server 10. Although two disk drive racks 50 areprovided according to this embodiment, a single rack 50 or three or moreracks 50 also can be provided according to the invention.

Beneath disk drive racks 50, power supply rack 60 supports a pluralityof hot-swappable power supplies 65, also referred to as power supplyelements, as well as system management unit 70. System management unit70 includes a maintenance/management computer that performs a number offunctions, as will be described. Between one and three power supplies 65can be provided, depending upon the degree of redundancy desired and onthe amount of power drawn by data server 10. Generally, the maximumnumber of power supplies 65 required by data server 10 is two, so that athird power supply 65 can be provided to create redundancy. The heaviercomponents of data server 10, i.e., power supplies 65, system managementunit 70, and disk drives 57, are placed low in the machine to keep theoverall center of gravity lower and thus provide greater stability.

As shown in the Figures and as described above, peripheral rack 40preferably is a topmost rack, and card cage rack 45 preferably islocated immediately underneath peripheral rack 40. This positioning isvery convenient for the user and represents a significant improvementover many prior art devices, because peripheral rack 40 typically is theportion of data server 10 that is accessed most often. Users typicallyaccess peripheral rack 40, for example, to replace/reload a back-updrive or a floppy drive, to copy data on or off data server 10, or toload new software. Placing peripheral rack 40 at the topmost position ofdata server 10 makes rack 40 much more convenient to access, whether theuser is standing or sitting, and eliminates the need for the user tobend down to the floor, for example.

Of course, access to card cage 47, which as described above includesmany valuable components, also is important. Therefore, peripheral rack40 advantageously is mounted on slides 42, to linearly move from ahoused position, at least partially within housing 15, to an extendedposition, at least partially outside housing 15. Note, for example,arrows 44 in FIG. 6, which show the linear movement of peripheral rack40 from its housed position toward its extended position.

Sliding peripheral rack 40 from its housed position to its extendedposition allows access to logic chassis 45 from the top of data server10. Logic chassis 45 preferably includes cover 46, pivotable on hinge 49(FIGS. 16-17) in the direction of arrow 48 (FIG. 6) when peripheral rack40 is moved out of the way to its extended position. Upon swinging logicchassis cover 46 to its open position, logic chassis 45 is fullyaccessible from the top of data server 10.

The sliding peripheral rack and underlying card cage according to theinvention overcome a number of disadvantages associated with prior artmachines. In most prior art machines, the card cage rack is located asthe topmost component for two reasons: (1) to facilitate access to thelogic chassis through the top or front of the machine, and (2) toincrease heat dissipation, as most of the heat energy is generated bythe logic chassis. If, for example, card cage rack 45 were immediatelybehind peripheral rack 40 instead of underneath it, accessibility wouldincrease, but the overall footprint of the machine would also increase.Alternatively, if peripheral rack 40 and card cage rack 45 were spacedsufficiently to allow better access to each, up to 30-40% empty spaceinside the housing would result. Serviceability and accessibility,therefore, would come at the expense of compactness. By placing cardcage rack 45 underneath peripheral rack 40 and providing structure toallow peripheral rack 40 to slide linearly to an extended position, dataserver 10 according to the invention combines compactness andserviceability in a manner unmatched in the prior art.

The racks and rack-mounted components of data server 10 preferably areone hundred percent serviceable from the front, top and rear sides ofthe data server, via front, top and rear doors 20, 30 and 35. For themost common servicing that data server 10 is likely to require in itslifetime, therefore, no access through side walls 25, 27 will benecessary. This also represents a significant advantage over prior artmachines. Because no access via side walls 25, 27 is required, aplurality of immediately adjacent data servers 10 can be arrangedside-by-side to form a row 12 of data servers, as shown, for example, inFIG. 18. Unlike many prior art data server arrangements, in which 3-6feet of space is required between machines and/or the machines have tobe unplugged and rolled out of the row for service, data servers 10according to the invention can be arranged immediately adjacent to oneanother, even touching each other, and still be one hundred percentserviceable without being moved. To allow top and front doors of dataserver 10 to be swung open without interfering with an immediatelyadjacent server or other object, each door includes a preferred hingearrangement, as will be described.

To prevent unauthorized access to the data server components through topdoor 30, front door 20 and top door 30 preferably overlap, so that topdoor 30 physically cannot be opened until front door 20 is unlocked andopened. Front door 20 preferably includes lip 80 (as shown in FIG. 4) atits upper rear side, and top door 30 preferably includes an abuttingsurface or flange 85, preferably at its front side. When top door 85 isin its closed position and front door 20 is then closed, lip 80 overlapsabutting surface 85 to prevent top door 30 from opening. Thus, both topdoor 30 and front door 20 are effectively secured by a single lock 90.According to a reverse embodiment, however, top door 30 can include alock and be configured with a lip, to overlap and/or engage a protrudingsurface on front door 20 and thereby prevent front door 20 from opening.Thus, top door 30 and front door 20 are interlockable with each other,such that when top door 30 and front door 20 are in their closedpositions, one of top door 30 and front door 20 locks the other of topdoor 30 and front door 20 in its closed position. Thus, one lock, 90 inthe illustrated embodiment, controls access to both the front and top ofdata server 10.

Data server 10 also preferably includes one or more detection devices,such as microswitches, coupled with various selected doors and/or locksto detect attempted access to the internal components of data server 10from the outside. According to one embodiment, the detection devicessignals system management unit 70 upon unlocking and/or opening of adoor, indicating that an attempt at access is occurring. Systemmanagement unit 70 then can take appropriate action, chosen by theoperator, such as signaling one or more persons or other computingdevices, lighting one or more lights 115 on light bar 105 (e.g., FIGS. 3and 6), initiating a complete or partial power-down of the machine,alerting law enforcement agencies, altering the physical characteristicsof the room in which the data server is located, or taking otherappropriate and/or preventive action.

In the example of the illustrated embodiment, data server 10 preferablyincludes one or more of the following detection devices: device 95 (e.g.FIG. 4), which detects unlocking of front door 20, device 97 (e.g. FIG.4), which detects opening of front door 20, device 98 (e.g. FIG. 4),which detects opening of top door 30, device 99 (e.g. FIGS. 4 and 5),which detects opening of rear door 35, device 96 (e.g. FIGS. 3 and 4),which detects opening of peripheral door 75, and/or device 94 (e.g. FIG.6), which detects opening of card cage lid 46. Although devices 94 and96-99 are shown in specific locations in the illustrations, alternativeplacements, at a variety of locations, are also contemplated.

Typically, the components of data server 10 that are the most importantto protect are located behind front door 20, and are accessible onlyafter unlocking and opening front door 20. For example, hard disk drives57 and system management unit 70 are both relatively expensive and aremost susceptible to unauthorized outside access to the data files beingstored on data server 10. Therefore, hard disk drives 57 and systemmanagement unit 70 are accessible only upon unlocking and opening frontdoor 20. System interrupt switches, such as system reset switch(es),system abort switch(es), and/or system off switch(es), also are behindfront door 20, preferably at location 100 as shown in FIG. 6. On-switch110 is on light bar 105 and thus accessible through peripheral door 75without opening front door 20, according to the illustrated embodiment,because data typically cannot be corrupted by turning data server 10 on.Alternatively, however, on-switch 110 also can be located behind frontdoor 20, and/or an off switch can be located so as to be accessiblewithout opening front door 20.

The internal modules of card cage 47 and other such components areaccessible only through top door 30, but top door 30 is not openableuntil front door 20 is opened, as described earlier. By placing the mostcritical and valuable components and switches under lock and key, and byconstant monitoring of the locked and/or closed states of the doors bythe detection devices, data server 10 according to the inventionachieves significant security advantages over the prior art.

To prevent data server 10 from overheating, thermal controls areemployed to maintain internal temperatures within a desired range. Tothis end, data server 10 includes a plurality of fans, positioned at thefront and rear sides of housing 15, to move air from outside the frontof housing 15, through mesh structure 23 in front door 20, toward therear of housing 15, and finally through a plurality of vents (not shown)in rear door 35. By providing a front-to-back airflow instead ofback-to-front or bottom-to-top airflow, as in many prior art devices,very little if any heated air is recirculated into the server from thearea immediately behind it, or is recirculated within the server fromrack to rack. Instead, cold air is pulled off the front of the machineand transferred out the back of the machine, without significant mixingof ambient cool air with heated air. This becomes especially importantwhen data server 10 is located in a room without traditionalcomputer-room air controls, such as a personal office, or even a roomwithout any air conditioning whatsoever.

FIG. 4 illustrates a number of fans at the front of server 10. Eachpower supply 65 preferably includes its own fan 66, for drawing air fromthe front of the server and directing it toward the rear of the serverthrough the power supplies. Card cage rack 45 also supports a pluralityof fans 41, moving air from the front of the machine, through card cage47 and toward the rear. At the rear of server 10, as shown in FIG. 5,for example, each disk drive rack 50, 55 supports a plurality ofrear-mounted fans 58, which draw air from inside the disk drive racks,and thus from the front of disk drive racks 50, 55, and transfer it outthe rear of the machine. Thus, in a full-fan configuration, data server10 includes a total of ten fans: three card cage fans 41 and three powersupply fans 66 at the front of the machine, and four disk drive rackfans 58 at the rear of the machine. Of course, other numbers andarrangements of fans also are contemplated.

Although peripheral rack 40 is generally convection cooled and includesa number of vent holes in door 75, for example, which allow some minimalairflow to escape out the front of the machine due to back pressurewithin the machine, the primary airflow generated by the up to ten fansof the data server is front-to-back.

Disk drive rack fans 58 preferably are hot-swappable and/or redundant.Thus, for example, although two fans 58 are provided for each disk driverack 50, 55, each rack needs at a minimum only one of the two fans tocool properly. Further, a malfunctioning fan can be changed withoutshutting off the power to data server 10. Each fan preferably includes adead-fan sensor that is continuously monitored by system management unit70. Upon detecting failure one of fans 58, an appropriate alarm issounded and/or an operator is otherwise notified.

Each card cage fan 41 preferably services approximately one-third ofcard cage 47. These fans generally are not redundant, according to oneembodiment, and therefore each preferably includes a tachometer thatrecords r.p.m.'s and, upon deviation of fan speed from a predeterminednorm, signals system management unit 70 that failure is imminent. Systemmanagement unit 70 can, in addition to signaling an operator in theevent of fan failure, power-down the machine once one or more fans 41have been functioning inadequately for a given period of time. Fans 41preferably are hot-swappable and, of course, can be chosen andpositioned to provide redundancy if so desired.

Preferably, system management unit 70 continuously monitors all fans ofdata server 10, except the power supply fans according to a preferredembodiment, by tachometers, dead-fan signals or other monitoringdevices. Server 10 also preferably includes a plurality of temperaturesensors that are controlled and continuously monitored by systemsoftware executing in system management unit 70. Two temperature sensorspreferably are located within card cage 47, one of which reads incomingair temperature, i.e. ambient temperature, and one of which readsexiting air temperature. Two additional temperature sensors preferablyalso are provided, at the back of data server 10 according to apreferred embodiment, one of which is immediately below card cage 47 andthe other of which is at the top of data server 10. System managementunit 70 can be programmed to initiate a variety of actions based on thetemperature sensor outputs, for example powering down the machine,sending warnings, etc. The ambient air sensor, in particular, may alsoserve as a fire sensing device, for example.

As discussed previously, preferred hinge arrangements are provided toallow the top and front doors of data servers 10 to be swung openwithout interfering with an immediately adjacent server or other object.Additionally, the hinge arrangements preferably are hidden from viewwhen the top and front doors are in their closed positions, to reducethe likelihood of tampering. FIGS. 4A-4B illustrate upper and lowerfront door hinges 120, 130 and top door hinges 135, to achieve thesepurposes.

As shown in FIG. 4A, lower front door hinge 120 includes hinge plate123, which preferably is bolted or otherwise attached to housing frame15. Attached to hinge plate 123 and preferably integral as one-piecetherewith is hinge plate 124, which includes a stepped, cutout portion125. Front door 20 includes a corresponding protrusion block 138, whichfits into cutout portion 125 underneath hinge plate 124 when front door20 is in a closed position. The engagement between the top side ofprotrusion 138 and the lower side of hinge plate 124 at cutout 125prevents vertical removal of front door 20 when it is in its closedposition. As door 20 is moved toward its open position, protrusion 138swings out from under hinge plate 124 to allow front door 20 to belifted vertically off hinge 120 and completely removed from housing 15,if so desired. Hinge 130 thus enhances the overall security of dataserver 10, because front door 20 cannot be removed without beingunlocked and opened, thereby triggering the various detection devicesdescribed previously. It should also be understood that, although hinges130 are only shown on front door 20, it is also contemplated thatsimilar hinges 130 could be provided for rear door 35.

As shown in FIG. 4B, uppermost front door hinge 130 includes hingeplates 133, 134, which preferably are integrally connected to form aone-piece structure. Hinge plate 134 supports front door 20 at its uppercorner, preferably in a manner similar to that described for lower hinge120.

Each top door hinge 135 includes hinge plates 140, 145, which are boltedor otherwise affixed to top door 30 and housing frame 15, respectively.Hinge plates 140, 145 are pivotally connected by hinge pin 150, whichincludes an upturned end portion 155 to provide a gripping surface foreasy removal of pin 150 and therefore top door 30. Top door hinges 135allow top door 30 to open without interfering with an adjacent dataserver or other object, while keeping hinges 135 hidden from view whentop door 30 is closed.

Because data server 10 according to the invention is considerably morecompact than its predecessors, it is considerably shorter and thereforemore likely to receive beverage cups and other objects on the outsidesurface of top door 30. To minimize the potential for spilled liquid toenter data server 10 and damage valuable internal components, therefore,data server 10 preferably includes a guttering system supported byhousing frame 15 just underneath top door 30. The guttering systempreferably is in the form of a square-shaped ridge formed by fourseparate or integral metal pieces running around the top of frame 15.Left- and right-side gutter ridges 157 (FIG. 4B), 158 (FIG. 6) form twosides of the square-shaped ridge, and similar gutter ridges (not shown)extend along the forward and rear sides of frame 15 to complete thesquare. Additionally, the guttering system aids in electro-magneticinterference (EMI) sealing of at least the lid area of data server 10.

According to a preferred embodiment, the data server components andinternal wiring of data server 10 are arranged so that almost no wiresare visible through the front, top or rear doors. All or substantiallyall of the power-associated components, such as power supplies 65 arelocated on the right-hand side of the machine, and the correspondingwiring runs behind at least one cover plate on the right-hand side ofthe machine. Similarly, all or substantially all of the I/O-associatedcomponent wiring is positioned to run behind at least one cover plate onthe left-hand side of the machine. Additionally, approximately 80-90% ofall the wiring is positioned in the very bottom portion of the machine,underneath bottom rack 60. By hiding all but approximately 2% of themachine wiring, a very neat and clean appearance is presented to thetechnician, unlike many prior art data servers. Additionally, thenon-exposed wiring of data server 10 is less likely to suffer damagethan the exposed and tangled wiring of many prior art servers.

Data server 10 according to the invention preferably is fully wired forits maximum configuration, i.e., for its maximum number of components,so that the wiring need not be changed or upgraded upon upgrading themachine.

Data server 10 according to the invention also preferably includes I/Oconnection arrangement 160 (FIG. 9A) at the back of server 10.Arrangement 160 includes patch panels 165 attached to the rear side ofeach disk drive rack 50, 55, and includes corresponding side patchpanels 170 at the side of housing frame 15, extending substantiallyperpendicular to disk drive patch panels 165. Each patch panel 165, 170preferably includes four connectors 166, for attachment to ribbon cableor other signal-relaying material.

As shown in FIG. 9, for example, data server 10 also includes a bulkhead175, for connecting external wires to data server 10, for example.Bulkhead 175 preferably includes external I/O, with eight channelspreferably available, serial ports, with four being preferable, and UPSsupport connections. Thus, bulkhead 175 enables external connection evenwith rear door 35 closed.

A number of I/O channels, for example eight, may be connected internallyto card cage 47. Half of the channels, for example four, are coupledwith bulkhead 175 for connection to external devices. The other halfdrop to internal patch panel 170. According to this example, twochannels drop to the level of each disk drive rack 50, 55. There is alsoa corresponding adjacent drop to each of these on a patch panel thatconnects to bulkhead 175. Preferably by use of patch cabling, an I/Ochannel or channels can be connected to either or both disk drive racks50, 55, and/or bulkhead 175, in various arrangements to achieve resultsdesired by the operator of data server 10. At least 28 practicalcombinations and/or arrangements exist, according to a preferredembodiment.

Each disk drive rack 50, 55 is broken logically into halves, and/or hastwo I/O channels, so that up to five, half-height devices (e.g. 1.75inches thick by 5.75 inches wide) can be connected on each channel. Thetwo channels inside the rack can be "patched" together on the outside ofthe rack to put ten devices on the same channel. All power and fansignal connections preferably are made by one panel-mounted connector onthe back of the rack. The fans are designed such that left and right fansignals can not be mixed or exchanged. As shown in FIG. 9, for example,data server 10 also includes a bulkhead 175, for connecting externalwires to data server 10, for example. Bulkhead 175 preferably includesexternal I/O, with eight channels preferably available, serial ports,with four being preferable, and UPS support connections. Thus, bulkhead175 enables external connection even with rear door 35 closed.

As shown in FIG. 7, data server 10 according to the invention preferablyincludes alternating current cord retention device 200, for the cordpreferably provided with the machine. Device 200 preferably is fixed toframe 15 with a swivel half that prevents unintentional removal of theplug.

Data server 10 according to the invention also preferably includesshock-absorbing and/or movement-dampening devices (not shown), such asstruts, for example, for at least front and top doors 20, 30. Accordingto one embodiment, a pneumatic piston-cylinder assembly extends betweenbracket 180 on top door 30 and a lower bracket (not shown) attached tothe left side of housing frame 15, for example directly below bracket180 as viewed in FIG. 4, immediately adjacent gutter ridge 157.Similarly, a pneumatic piston-cylinder assembly preferably extendsbetween a bracket on the inside of front door 20, centered on the doorjust below peripheral access door 75, horizontally over to a similarbracket at the left-hand side of frame 15. Such devices prevent damagedue to slamming and/or overextending doors 20, 30, and hold the doors inopen or partially open positions on their respective hinges.

FIGS. 10-17 illustrate racks 40, 45, 50, 55 and 60 in greater detail.FIGS. 10-11 are assembled and exploded views, respectively, ofperipheral rack 40. According to the illustrated embodiment, disk drives241, floppy drive 243 and CD ROM drives 245 preferably are housed withinperipherals cage 247, which includes front and rear plates 242, 249. Theperipheral devices preferably slide into cage 247 from the front. Floppydrive 243 additionally can slide in from the back on rails, for example,for ease of installation and removal. Cage 247 and rear plate 249include a plurality of vents 253, for promoting better air flow throughperipheral rack 40. Cage 247 is supported within housing frame 15 bymounting plates 244, which linearly move along slides 42 in a mannerpreviously described. Of course, cage 247 and front and/or rear plates242, 249 can be configured to accommodate any desired number and typesof peripheral storage devices 241, 243, 245.

FIGS. 12-13 are assembled and exploded views, respectively, of diskdrive rack 50, according to a preferred embodiment. Individual hard diskdrives 57 are housed within drive cage 56, which includes an upperopening covered by access plate 59 and rear openings for accommodatingdisk drive fans 58.

FIGS. 14 and 15 are assembled and exploded views, respectively, of powersupply rack 60. Individual power supply units 65 and system managementunit 70 are housed within cage 261, which is covered by side plates 262,top and bottom plates 263, 264, and rear plate 265, which preferably isa self-aligning hot-plug connector plate. Rack 60 also includes coverplate 270, for covering and protecting system management unit 70.

FIGS. 16-17 are front and rear perspective views, respectively, of cardcage rack 45. Card cage rack 45 includes lid 46 hinged at 49, asdescribed previously. Card cage fans 41 push air through card cage 47 toexit at vents 255 in rear plate 256 and lid 46. Rear plate 256 alsoincludes slots 257, for allowing connection to inserted components, forexample daughter cards.

While the invention has been described with reference to specificembodiments, the description is illustrative and is not to be construedas limiting the scope of the invention. For example, a variety ofmaterials can be used for the various parts of the invention, includingthe skins, frame and racks. Further, a wide variety of data servercomponents are usable, not just those illustrated and described. Variousother modifications and changes may occur to those skilled in the artwithout departing from the spirit and the scope of the invention asdefined in the following claims.

What is claimed is:
 1. A rack-mount data server comprising a singlecomputer unit, the server comprising:a housing; a plurality of dataserver components supported by the housing, the components comprising atleast one peripheral storage device, a logic chassis for the dataserver, at least one disk drive on which the data server stores files,and a power supply comprising at least one power supply element, theplurality of data server components being contained within the singlecomputer unit and being powered by the power supply; and a plurality ofracks coupled with the housing to accommodate the data servercomponents, the racks including a first topmost rack accommodating theat least one peripheral storage device, a second rack accommodating thelogic chassis, and a third rack accommodating the power supply, thehousing supporting the second rack underneath the first rack as thesecond topmost rack, the at least one peripheral storage device of thedata server being accommodated only by the first topmost rack, and thelogic chassis of the data server being accommodated only by the secondtopmost rack, wherein the first rack is supported by the housing to movefrom a housed position within the housing to an extended position atleast partially outside the housing to allow access to the logic chassisfrom the top of the data server, further wherein the second and thirdracks are supported by the housing to move from respective housedpositions within the housing to respective extended positions at leastpartially outside the housing.
 2. The data server of claim 1, whereinthe at least one disk drive comprises a plurality of plug-and-play diskdrives.
 3. The data server of claim 1, wherein the housing includes aplurality of slides, the first rack being mounted on the slides tolinearly move to the extended position.
 4. The data server of claim 1,wherein the logic chassis includes a cover, the cover being movable toan open position when the first rack is moved to the extended position.5. The data server of claim 4, wherein the cover is pivotally mounted tothe logic chassis to swing into a space occupied by the first rack inits housed position.
 6. The data server of claim 1, wherein the at leastone peripheral storage device is selected from the group comprisingfloppy disk drives, CD ROM drives, boot drives, and tape drives.
 7. Thedata server of claim 1, wherein the data server housing furthercomprises a front door covering a front side of the data server; furtherwherein the front door comprises an openable peripheral access doorseparate from the front door to allow access to the first rackaccommodating the at least one peripheral storage device.
 8. The dataserver of claim 7, wherein the front door is pivoted with respect to theremainder of the housing by at least one internal hinge to preventcontact of the front door with an object adjacent a lateral side of thedata server.
 9. The data server of claim 1, further comprising anopenable front door, an openable back door and an openable top door toallow access to all of the data server components from the front, backand top of the data server.
 10. The data server of claim 1, furthercomprising:a front door positioned to cover a front side of the dataserver when the front door is in a closed position and to allow accessto the plurality of racks from the front side of the data server whenthe front door is in an open position; and a top door positioned tocover a top side of the housing when the top door is in a closedposition and to allow access to the racks from the top side of thehousing when the top door is in an open position, the top door and thefront door being interlockable with each other such that when the frontdoor and the top door are in their closed positions, the front doorlocks the top door in its closed position.
 11. The data server of claim10, further comprising:a peripheral access door disposed within thefront door of the data server to allow access to the first topmost rack;and at least one detection device coupled with the peripheral accessdoor and with a system management unit to signal the system managementunit upon attempted access to the first topmost rack via the peripheralaccess door.
 12. The data server of claim 10, wherein the front door ofthe data server comprises a lip and the top door of the data servercomprises an abutting surface, the lip overlapping the abutting surfacewhen the front door and top door are in their closed positions toprevent the top door from opening.
 13. The data server of claim 10,further comprising:a system management unit as one of the plurality ofdata server components; and at least one detection device, coupled withone of the top door and the front door and with the system managementunit, to signal the system management unit upon attempted access to dataserver components from outside the data server via said one door. 14.The data server of claim 13, wherein said one door includes a lock, theat least one detection device signaling the system management unit whenthe lock is unlocked.
 15. The data server of claim 13, wherein the atleast one detection device signals the system management unit when saidone door is opened.
 16. The data server of claim 13, wherein the atleast one detection device comprises a microswitch.
 17. The data serverof claim 1, wherein the logic chassis comprises an openable logicchassis cover disposed within the housing; the data server furthercomprising a detection device coupled with the logic chassis cover andwith a system management unit to signal the system management unit uponattempted access to the logic chassis via the logic chassis cover. 18.The data server of claim 1, wherein the logic chassis comprises aplurality of printed circuit modules that are inaccessible from the backof the data server.
 19. The data server of claim 1, further comprising:afront door coupled with the housing to cover a front side of the housingwhen the front door is in a closed position and to allow access to atleast one of the data server components from the front side of thehousing when the front door is in an open position, the front doorincluding a mesh structure on at least a portion of an exterior surfaceto allow airflow through the front door; and a plurality of fanspositioned adjacent the front side of the housing to move air fromoutside the front of the housing, through the mesh structure of thefront door, toward the back side of the housing.
 20. The data server ofclaim 19, wherein the data server components further comprise a systemmanagement unit and wherein at least one of the plurality of fanscomprises a fan speed sensor coupled with the system management unit tosignal the system management unit upon deviation of fan speed from apredetermined level.
 21. The data server of claim 19, wherein the meshstructure extends substantially the entire length of the front door toallow airflow therethrough.
 22. The data server of claim 1, furthercomprising a plurality of fans positioned adjacent a back side of thehousing to move air to the back side of the housing.
 23. The data serverof claim 1, further comprising:a front door positioned to cover thefront side of the housing when the front door is in a closed positionand to allow access to the plurality of disk drives from the front sideof the housing when the front door is in an open position; and at leastone hinge coupled with the front door and with the housing to cause thefront door to open without interfering with an immediately adjacent dataserver.
 24. The data server of claim 23, wherein the at least one hingedefines a substantially vertical pivot axis passing through an edge ofthe front door.
 25. The data server of claim 23, wherein the at leastone hinge comprises a stepped section and the front door comprises aprotrusion, the protrusion being located within the stepped section ofthe at least one hinge to prevent vertical removal of the front doorwhen the front door is in its closed position, the protrusion beingremoved from the stepped section of the at least one hinge to allowvertical removal of the front door when the front door is in its openposition.
 26. The data server of claim 1, wherein the housing furthercomprises a top side; further wherein the data server comprises:a topdoor positioned to cover the top side of the housing when the top dooris in a closed position and to allow access to at least one of the dataserver components from the top side of the housing when the top door isin an open position; and at least one hinge coupled with the top doorand with the housing to cause the top door to open without interferingwith an immediately adjacent data server.
 27. A rack-mount data server,comprising:a housing; a plurality of data server components supported bythe housing, the components comprising at least one peripheral storagedevice, a logic chassis for the data server, at least one disk drive onwhich the data server stores files, and at least one power supply; aplurality of racks coupled with the housing to accommodate the dataserver components, the racks including a first topmost rackaccommodating the at least one peripheral storage device and a secondrack accommodating the logic chassis, the housing supporting the secondrack underneath the first rack as the second topmost rack; and a frontdoor covering a front side of the data server, the front door comprisingan openable peripheral access door separate from and within the frontdoor to allow access to the first rack accommodating the at least oneperipheral storage device; wherein the first rack is supported by thehousing to move from a housed position within the housing to an extendedposition at least partially outside the housing, further wherein thesecond rack is supported by the housing to move from a housed positionwithin the housing to an extended position at least partially outsidethe housing.
 28. The data server of claim 27, wherein the openableperipheral access door is constructed to allow access only to the firstrack accommodating the at least one peripheral device.
 29. A rack-mountdata server, comprising:a housing; a plurality of data server componentssupported by the housing, the components comprising at least oneperipheral storage device, a logic chassis for the data server, at leastone disk drive on which the data server stores files, and at least onepower supply; and a plurality of racks coupled with the housing toaccommodate the data server components, the racks including a firsttopmost rack accommodating the at least one peripheral storage deviceand a second rack accommodating the logic chassis, the housingsupporting the second rack underneath the first rack as the secondtopmost rack; wherein the first rack is supported by the housing to movefrom a housed position within the housing to an extended position atleast partially outside the housing, to allow access to the logicchassis from the top of the data server; the data server furthercomprising a logic chassis cover, the cover being movable to an openposition when the first rack is moved to the extended position, thecover being pivotally mounted with respect to the logic chassis to swinginto a space occupied by the first rack in its housed position.
 30. Arack-mount data server, comprising:a housing; a plurality of data servercomponents supported by the housing, the components comprising at leastone peripheral storage device, a logic chassis for the data server, atleast one disk drive on which the data server stores files, and at leastone power supply; and a plurality of racks coupled with the housing toaccommodate the data server components, the racks including a firsttopmost rack accommodating at least one of the data server componentsand a second rack accommodating at least one of the data servercomponents, the housing supporting the second rack underneath the firstrack as the second topmost rack; wherein the first rack is supported bythe housing to move from a housed position within the housing to anextended position at least partially outside the housing, to allowaccess to the at least one data server component accommodated by thesecond rack from the top of the data server; the data server furthercomprising a second rack cover, the cover being movable to an openposition when the first rack is moved to the extended position, thecover being pivotally mounted with respect to the second rack to swinginto a space occupied by the first rack in its housed position.
 31. Arack-mount data server comprising a single computer unit, the servercomprising:a housing; a plurality of data server components supported bythe housing, the components comprising at least one peripheral storagedevice, a logic chassis for the data server, at least one disk drive onwhich the data server stores files, and a power supply comprising atleast one power supply element, the plurality of data server componentsbeing contained within the single computer unit and being powered by thepower supply; and a plurality of racks coupled with the housing toaccommodate the data server components, the racks including a firsttopmost rack accommodating the at least one peripheral storage device, asecond rack accommodating the logic chassis, and a third rackaccommodating the power supply, the housing supporting the second rackunderneath the first rack, the first topmost rack accommodating only theat least one peripheral storage device of the data server, and thesecond rack accommodating only the logic chassis of the data server,wherein the first rack is supported by the housing to move from a housedposition within the housing to an extended position at least partiallyoutside the housing to allow access to the logic chassis from the top ofthe data server, further wherein the second and third racks aresupported by the housing to move from respective housed positions withinthe housing to respective extended positions at least partially outsidethe housing.